Built-in plastic bath tub structure



May 7, 1963 R. H. LONG 3,088,124

BUILT-IN PLASTIC BATH TUB STRUCTURE Filed June 8, 1961 2 Sheets-Sheet 1i 2 INVENTOR.

RICHARD H. LONG i fl ATTORN Y May 7, 1963 R. H. LONG BUILT-IN PLASTICBATH TUB STRUCTURE 2 Sheets-Sheet 2 Filed June 8, 1961 Po m 3 T O 2 7 ML l V w w m H K I. D 3 6 4 m z 3 2 H w 11F415 w QV 2 l/m mw fiw flva m BR 7x. v 8 a ll Y 7a 2 I m B 3 l m d o 0 mm 3\ B n z n 3 t. M. I 4 u a Bu 8 2 ATTORNEY United States Patent ice 3,038,124 Patented May 7, 19633,088,124 BUILT-IN PLASTIC BATH TUB STRUCTURE Richard H. Long, Phoenix,Ariz., assignor to Plastrglas Mfg. Co., Tempe, Ariz., a corporation ofArizona Filed June 8, 1961, Ser. No. 115,638 2 Claims. (Cl. 4-173) Withthe advent of modern plumbing and daily bathing, bath tubs became asubject of intensive development to produce an elieotive piece ofequipment at a relatively reasonable price. As a consequence, bat-h tubshave for the last several decades gene-rally comprised a cast orfabricated ferrous structure with a coat of fired porcelain enamel. Atone time bath tubs were separate from the room in which they were used,and were supported on a suitable base set on the floor; but, with theadvent of modern plumbing conveniences including. combination tubs andshowers, bath tubs have been designed to be mounted directly onto thecfioor and built into the room itself, so that only a curtain along oneside is necessary to prevent splashing of shower water onto the floor.

In the so-called built-in tub, the tub itself is first roughed in and alayer of tile is then commonly set around three sides of the tub, thetile usually extending from the top edge of the tub to a suitableheightusually five or six feet above the floor line. Such tile not onlyhas the efiect of providing a pleasing appearance, but it is functionalin protecting the wall of the bathroom by draining all water splashedfrom the tub or shower back into the tub itself for eventual drain-age.Because of this arrangement there has usually been a cementitious jointbetween the bottom course of tile and the tub to prevent water leakagebetween the tile and tub. A tiled hath not only is relatively costly,but it has the further disadvantage that in the course of time therelative expansion and contraction of the various parts of theinstallation will gradually cause the cementitious material between thetub and tile to crack and thus permit water leakage around the top ofthe tub.

It is accordingly a principal object of my present invention to providean improved built-in bath tub.

Another object is the provision of an improved built-in bath tub inwhich there is no dilferential expansion of contiguous members such asto cause cracking and leakage.

A further object is the provision of an improved builtin bath tub whichcan be installed at greatly decreased cost as contrasted with built-inbath tubs of the prior art.

Other specific objects and features of my invention will be apparentfrom the following detailed description taken with the accompanyingdrawings: wherein FIG. 1 is an isometric view showing a preferred formof bath tub of the present invention;

FIG. 2 is a plan sectional view taken on the line 2- 2 of FIG. 1lookingin the direction of the arrows;

FIG. 3 is a longitudinal vertical sectional view taken on the line 3-3of FIG. 1;

FIG. 4 is a slightly enlarged fragmentary sectional view showing astructural feature;

FIG. 5 is a bottom plan view;

FIG. 6 is a fragmentary sectional view taken on the line 6-6 of FIG. 1,and

FIG. 7 is a sectional view similar to FIG. 3, but showing amodification.

In accomplishing the objects of the invention I produce a single pieceunitary plastic structure including a tub member 10, side members 11 and12, and a rear wall 13. The tub 10 is preferably finished in white tohave the appearance of white porcelaimalthough other colors may beutilized simulating types of colored porcelain enamels. The walls 11through 13, while having other features and functions, generally providethe same function and may havethe same appearance as the commonlyprovided tile which is normally laid on the wall around and above thetub. As mentioned, this is a single piece unitary body which is merelyset into a suitable space provided in the bathroom and the entirestructure mounted permanently in place as will be described.

Before referring to structural features I wish to explain briefly themanner in which the unitary body is produced. A mold is first formedwhich is the mirror image or reverse of the finished portion of theunitary device. Looking at FIG. 1, the mold would fit within the areathere shown. It should be noted further that, from the device shown inFIG. 1, a mold can be formed by spraying the exterior smooth face of theunitary device with a suitable plastic material, permitting it to setsuitably, and then removing it. Because of the stresses and strainsincident to molding, however, the mold is suitably reinforced, all inaccordance with methods known in the plastic industry.

Once the mold has been produced and has had its surface against whichthe plastic is to be applied finished with extreme smoothness, a coat ofwax or other material to form a parting film is applied to it to preventsticking and the portion of the mold which will form the tub 10 is thensuitably masked to prevent the initially applied plastic material fromreaching it. The portion of the mold forming the Walls '11 through 13 isthen sprayed with a clear plastic, such as a clear polyester resin. Thisclear coating is then sprayed or otherwise treated to form the design orfinish which will be desired on the walls. This finish can simulatetile; it can be a solid color, or it may be broken up to form a fleckappearance, depending upon the overall design. The exact manner offorming the decorative exterior wall surface under the clear plasticdepends to a considerable extent on the type of surface desired.Whatever the method of application,

the clear plastic coat and the decorative coat preferably are firstapplied to the walls while the tub portion is masked to preventaccidental application of an undesired color thereto.

The next step is to remove the masking material from the tub portion ofthe mold and spray the entire exterior of the mold with a dense whiteplastic, of which several commercial products are available. I havefound that the product known as Gel Coat white, in which very finelydivided titanium dioxide is the color medium, is very suitable for thepurpose. After the white coating has been applied and permitted to setfor a short time, I then apply a coating of black or colored plastic,using a polyester as in the previous applications. The colored coatinghas the efiect of showing up any irregularities such as bubbles whichmight have developed during the spraying of the white coating.

The next step is to spray a so-called fiberglass coat consisting ofglass fibers and polyester resin at relatively high pressure over theentire surface, followed by a finish coat of polyester resin. Ingeneral, the fiberglass coat is approximately inch thick, and the finishcoat inch thick at the sides and inch thick at the tub portion, althoughthese dimensions may vary somewhat. I also employ certain reinforcingfeatures, but the details of such reinforcement will be explained aftera more detailed description of the structure as a whole.

Looking now first at the tub portion, it includes a front skirt 16, anda tub portion consisting of a bottom wall 17, tapered back and frontside walls 18 and 19, and tapered .end walls 21 and 22. As may be seenparticularly in FIG. 3, the front skirt 16 is connected to the frontside wall'19 by a rounded top rim portion 23, and this rounded topportion runs entirely around the tub to simulate a standard porcelaintub shape. The skirt 16 is shaped to reinforce the structure and improveits appearance as FIGS. 1 and 2 show. The rounded upper rim portion 23runs entirely around the top of the tub, and while generally identicalin shape and appearance as the top rim of an ordinary porcelainizedmetal tub, it connects directly to the walls 11 through 13. The walls 11through 13 communicate with this rim through an integral angle strip 24which acts as a reinforcement and has the general appearance of theusual cementitious joint between the tub and wall tile.

As shown particularly in FIG. 4, the periphery of the walls 1 1 through13 at the top and sides has an integral projecting angular portion 26,with an integral offset projection 27 displaced from the plane of thewall proper approximately the thickness of a polyurethane backing strip28. The offset projection 27 may be provided with a plurality of holes29 for the passage of nails 31 to secure the entire device in place byattachment to the studding of the room in which the tub is installed. InFIG. 4 I indicate a section of such studding at 32 to show the manner inwhich nails may be driven through the attachment to secure the entireunitary bath tub assembly in place. After the bath tub assembly of thepresent invention is nailed or otherwise secured in position, plaster orplasterboard 33 is applied so that there is a finished appearancethroughout the entire periphery, and the walls 11 through 13 projectslightly from the Wall in the general manner of tile.

In the preceding paragraph I described the projecting angular portion 26and offset projection 27 which acts as an attachment strip. Looking atFIGS. 1 through 3 it will be noted that both the said angular projection26 and the attachment strip 27 extend peripherally entirely around thestructure except for the bottom of the skirt 16. The angle strip 24between the tub and side Walls also extend around to the front portionof the structure. For convenience of identification this extension ofthe angle strip 24 is indicated by the reference character 24 as itextends vertically upwardly and the contiguous end of the angularprojection 26 and attachment strip 27 are identified by the referencecharacters 26 and 27 respectively. It is obvious that unlike the tile inmost built-in bath tub installations the integral side walls 11 and 12extend somewhat in front of the tub so that the attachment strip 27assists in maintaining a very rigid assembly, but it also extends underthe plaster clear down to the floor or baseboard line and produces amuch improved installation, as contrasted with the conventionalinstallations of the prior art.

To reinforce the tub at the bottom I provide a plurality of reinforcingstrips 34 arranged to form a grid. The strips are preferably about inchthick and about two inches Wide, and may comprise various types ofmaterial. I have found a material like polyurethane foam plasticparticularly suitable for the purpose. When a material like polyurethanefoam plastic is used for the strips its function primarily is to producethe equivalent of a void in the structure so that a spaced stripstructure having a cantilever-like action is produced without addingsubstantially to the weight. In applying the strips the tub is firstfinished with a layer of fiberglass and a layer of plastic to a totalthickness of about A inch, after which the strips are set on the stillwet plastic to secure them in position. A fiberglass layer is thenapplied over the entire area to incapsulate the strips completely, andthis may be followed with a finishing plastic layer to produce the finalstructure. I may also apply the strips by means of a resinous adhesiveafter the plastic coating has dried, and then cover them with theincapsulating layers, or I may also apply the strips over the relativelythin fiberglass layer, covering the entire area with plastic, thenanother layer of fiberglass and finally with the finishing plasticcoating. I may also but less advantageously use a material which initself has considerable reinforcing action, such as a relatively thinnerfiberglass strip, but the foam-type strip is preferred and appears togive the most rigid construction with the least weight.

To reinforce the bottom of the skirt 16 I utilize a reinforcing strip36, and this may also be a strip of polyurethane foam, which is appliedin position after the strips 34 are partly incapsulated, the finalcoating of polyester resin being applied over the entire bottom surfaceincluding the reinforcing strip 36 to serve the effect both of holdingit in position and of partly strengthening it.

With further reference to the production of the unitary built-in bathtube of the present invention, it should be understood that the mold isshaped to extend within the tub and in contact with the faces forming acontinuation of the interior of the tube as they appear particularly inFIG. 1. During the molding operation, therefore, the parts will occupy aposition reverse to that shown in FIG. 1. In other words, the bottom ofthe tub will be at the top and the upper rim of the side walls 11through 13 at the bottom. This makes it impossible to completely finishthe bottom of the tub with the reinforcing strips 34 and 36 as theyappear in FIGS. 5 and 6 before the structure is removed from the mold.It will be noted that the peripheral angular projection 26 is, as aresult, partly recessed or under cut. Since the walls are relativelymore flexible, however, they can be sprung away from the mold if care isemployed to prevent cracking, it being obvious that for most efiicientuse of molds the completed tub must be removed before the plastic hasreached its maximum set. I have found that by forcing water between themold and the finished casting the latter may befioated away from themold and freely removed without damage to its surface or basicstructure. Other fluids comprising other liquids and gases underpressure can be used in the same way to separate the plastic coatingfrom the mold.

In general it is preferable that the backing strips 28 be applied afterthe casting has been removed from the mold. These backing strips are asuitable cushioning, strengthening and sound-deadening material, andpolyurethane foam in sheet form is very suitable for the purpose. Thethickness of the backing strips 28 is such that when the offsetprojection 27 is nailed to the studding or lathing the backing strips 28will be engaged between the structure of the building and the walls 11through 13. This makes a very firm and finished structure afterpermanent installation.

In FIG. 7 I show a modification in which the upper rim 123 extends onlyalong the front side of the tub between the skirt 116 and the front side'119 of the tub. For convenience and to shorten the description I haveapplied the same reference characters to the modification as employed inthe main embodiment with, however, the prefix 1 to indicatemodification. Those skilled in the art will understand that the ordinaryporcelain-covered iron or steel tub must have the top rim runningentirely around the tub to satisfy structural requirements and toprovide a surface against which the tile can abut when the tub isinstalled. As FIG. 7 shows, my invention permits the tub to be a directcontinuation of the side wall without a break if desired, or with anytype of discontinuity which may be desired from a straight appearancestandpoint, rather than from the standpoint of function. This featurepermits the over-all cost of the device to be reduced, makes possiblethe provision of a given tub size with less over-all space requirement,or actually the provision of a larger tub without the loss of space. Thetub assembly shown in the main embodiment in other words is in generaland in a fashion a replica of an installation comprising aporcelain-covered metal tub with tiled walls around it, but the unitarytub assembly of the present invention actually permits considerablesimplification and improvement of actual installations by simpleattachment of a complete unitary body within a building space shaped toreceive it.

While the terms used in the specification in general have theircustomary meaning, I employ the term built in in the title and in theclaims to identify a tub unit adapted to be built into a house, ratherthan one which is already built in. The term, therefore, is used as anadjective in the instances noted.

I have described my invention in detail so that those skilled in the artmay understand the manner of practising the same, but the scope of theinvention is defined by the claims.

I claim:

1. A built-in bath tube comprising a unitary plastic body having a tubeportion and three unitary wall members extending upwardly from the tub,said wall members having a laterally rcarwardly displaced attachmentstrip running entirely around the periphery of the wall members andcontinuing on down at sides of the tub to a floor line, and paddingmaterial adhesively secured to rear faces of said walls.

2. A built-in bath tube comprising a unitary plastic structure having atub portion with bottom, back and front side, and end walls, a skirtconnected to the front side wall by a rounded top rim, a grid shapedreinforcement body on a bottom outer surface of said tub bottom, saidreinforcement body resting directly on a bathroom floor a reinforcingstrip above the floor between said front side and a bottom portion ofsaid skirt, said rear side wall and end walls of the tub portion beingshaped to form rounded top rims comprising continuations of said roundedtop rim between said skirt and said front side, and end walls, a skirtconnected to the front forming generally right angular continuations ofthe end walls and rear side wall top rims, an integral peripheralangular forward projection from said side Walls extending downwardly atside edges of the tub skirt, an integral peripheral attachment stripdisplaced laterally from said integral peripheral projections andrearwardly from the wall members, said peripheral attachment stripadapted for attachment as by nailing to building structural members, andadapted to be covered by plaster and a cushioning backing strip securedto the rear of the room wall members and lying between the said roomwall members and building structural members when the attachment striphas been secured in place.

References Cited in the file of this patent UNITED STATES PATENTS2,100,568 Norris Nov. 1937 2,602,935 Phillips July 15, 1952 2,784,417Strand Mar. 12, 1957 2,899,687 Rossetti et a1. Aug. 18, 1959 3,010,116Cowley Nov. 28, 1961 3,015,110 Treand Jan. 2, 1962 FOREIGN PATENTS1,232,769 France Apr. 25, 1960

1. A BUILT-IN BATH TUBE COMPRISING A UNITARY PLASTIC BODY HAVING A TUBEPORTION AND THREE UNITARY WALL MEMBERS EXTENDING UPWARDLY FROM THE TUB,SAID WALL MEMBERS HAVING A LATERALLY REARWARDLY DISPLACED ATTACHMENTSTRIP RUNNING ENTIRELY AROUND THE PERIPHERY OF THE WALL MEMBERS ANDCONTINUING ON DOWN AT SIDES OF THE TUB TO A FLOOR LINE, AND PADDINGMATERIAL ADHESIVELY SECURED TO REAR FACES OF SAID WALLS.